How to make a lead screw?

When it comes to making lead screws, precision and efficiency are key. But how exactly are they manufactured? There are two key manufacturing methods: thread rolling and thread whirling—so you can better understand which method is best suited for your applications.

The Process of Thread Rolling a Lead Screw

Thread rolling is a highly efficient method of manufacturing lead screws, particularly suited for high-volume production. Unlike thread whirling, this process does not involve cutting the material. Instead, it utilizes cold forming, where the metal is shaped below its recrystallization temperature.

Here’s how it works:

1. Workpiece Positioning: A workpiece is placed centrally between two rotating tools.
2. Thread Formation: As the tools rotate, the thread profile is literally rolled into the surface of the raw material through compressive stress and rotation.

This method has several advantages:

• Cost-Effective for High Volumes: Lower material requirements make it faster and more economical.
• Enhanced Surface Quality: Cold forming hardens the surface, resulting in higher strength and durability.
• High Efficiency: The combination of pitch angle, superior surface finish, and low friction in plastics results in a long service life, making it the preferred option for many.

The Process of Thread Whirling

Thread whirling is another method used to create lead screws, offering a different set of benefits, especially when high precision is required. This process involves:

1. Tool Setup: A ring-shaped whirling tool is clamped around the workpiece.
2. Rotation: The workpiece rotates slowly while the whirling tool rotates at a much higher speed.
3. Thread Creation: Inward-facing cutting elements within the tool carve out the thread, creating a precise and well-defined profile.

Key advantages of thread whirling include:

• High Precision: Ideal for producing threads that demand particularly high surface quality.
• Versatility: Suitable for a wide range of thread geometries and materials, especially those that may not be well-suited for thread rolling.

Which Method Should You Choose?

Both thread rolling and thread whirling have their specific applications, and the right choice depends on your requirements. At igus®, we typically use thread rolling as our standard process due to its cost savings, better surface finish, and longer service life. However, for small quantities or threads requiring narrow tolerances, thread whirling may be the better option.

Configure Your Lead Screws with igus®

At igus®, we make it easy to design and configure the perfect lead screw for your needs. Our online configurators allow you to create custom solutions in just a few steps, and you can download CAD data and production drawings—all free of charge. No experience with CAD software? No problem! Our tools are user-friendly, and our experts are always on hand to provide assistance.

Ready to experience the quality of igus® lead screws firsthand? Order your free samples today and discover the difference our innovative manufacturing processes can make for your projects.